background image

Page 12

dIsAsseMbly ANd AsseMbly

 

1.  The brake tongue is assembled and adjusted at the factory:

 

 

 

 

Do Not Disassemble or Attempt to Adjust 

 

 

 

 

The Tongue Push-Rod Assembly (#11)

 

To disassemble the tongue:  (refer to illustration on page 15)

 

A.  Remove 3/4”bolts (#8) , remove stop block (#7), and pull  

 

 

male tongue (#30) out of female tongue (#1).

 

B.   Remove 1/2”bolt (#4), pin (#25), and spacer (#27)

 

C.   Remove set screw (#24) from adjustment spud (#23b),  

 

 

unthread and remove adjustment spud (#23b).

 

D.   Remove push-off assembly (#28), pin (#29), two shocks  

 

 

(#26), and two springs (#10).

 

E.  To remove tongue push-rod assembly (#11), master  

 

 

cylinder (#2), emergency lever (#14), pin (#15), spring  

 

 

(#16), and guide (#17), refer to section a&b of  “Servicing  

 

 

the Emergency Lever” on this page.  

 

To reassemble the tongue:  (refer to illustration on page 15)

 

A.  Replace 2 shocks (#26) into yoke (#28), with pin (29).

 

B.  Place 2 springs (#10), onto shaft of push-off assembly  

 

 

(#28), and insert shaft into female tongue (#1), through  

 

 

hole in plate (shown in exploded view).

 

C.  Thread adjustment spud (#23b) onto rear threaded   

 

 

portion of push-rod assembly (#28), until the 2 springs  

 

 

(#10) compress to a length of 6-1/2”.  Install and tighten  

 

 

set screw (#24), using Locktite, into one of the threaded  

 

 

holes of the spud (23b).

 

D.  Insert  pin (#25) into hole in tongue, through 1 shock (#26),  

 

 

through the spacer (#27), and through the other shock  

 

 

(#26) and tongue.  Install and tighten 1/2” bolt, lockwasher,  

 

 

and washer (# 4,5,6).

 

E.  Install master cylinder (#2), (refer to c-f of “Servicing  

 

 

Emergency Lever” section on this page).

 

F.  Thread adjust spud (23a) onto front threaded portion of  

 

 

push-rod assembly (#28).  Insert male tongue (#30),  

 

 

(with latch installed as shown), into female tongue (#1).   

 

 

Install stop block (#7), using 3/4” bolts and lockwashers  

 

 

(#8, #9). Pull male tongue (#30) forward to latched   

 

 

position and adjust spud (#23a) until there  is a 3/16” gap  

 

 

for 650/750 and 7/16” gap for 550 between spud (#23a) and  

 

 

rear stop surface of male tongue (#30) see arrow.

 

G.  Tighten set screw (#24),using Locktite,  into hole in spud  

 

 

(#23a).  

 

2.  Connect and tighten all brake lines.

 

3.  Fill the Master Cylinder (#2) with DOT 3 or 4 brake fluid.

 

4.  Bleed the brake system using a pressure-type brake  

 

      bleeder or manually, as follows:

 

a.  Remove the two Self-Tapping Screws (#18) and    

 

 

LockWashers (#19) that hold the Lever Guide (#17)  

 

 

and the flat Emergency Lever Spring (#16). Remove  

 

 

the Lever Guide and the Emergency Lever Spring.   

 

 

Using short strokes, pull forward on the Emergency  

 

 

Lever (#14), pumping the Master Cylinder until  

 

 

 

the brake fluid within the Master Cylinder stops bubbling.

 

b.  Attach a bleeder hose to the bleeder valve on one of  

deMco bRAKe ToNGue MAINTeNANce ANd AdjusTMeNT

                                Review all of the following instructions before installation and use of the hydraulic brake tongue. 
dealers or distributors must review these instructions with the ultimate user. failure to follow these instructions, 
or failure to properly maintain the braking system after installation, can result in loss of braking action which could 
cause severe property damage, personal injury and/or death.

 

the wheels (always begin with wheel farthest from the master  cylinder 
and move toward it).  Immerse the other end of  the hose into a 
clean, transparent container partially filled with brake fluid. Loosen 
the bleeder valve one turn and, watching the hose in the transparent  
container, use the Emergency Lever to pump the Master Cylinder 
as long as air bubbles continue to leave the hose. When the bubbles 
stop, close the bleeder valve, move to the next wheel, and repeat  
the process until all the brakes have been bled. (Note: Check the 
fluid level in the Master Cylinder frequently while bleeding the brakes 
(every 4 or 5 strokes). Refill as necessary to keep the level above 
half full.)

5.  Once bleeding is completed, refill the Master Cylinder and attach 

the Cap (#20) securely. Replace  Emergency Lever Spring, Lever 
Guide, with Lock Washers and Self-Tapping Screws.

 
6.  Test the brakes by pulling the Emergency Lever (#14) forward until it 

locks into its first detent position.  (The lever should be approximately 
straight  up.)    Attempt  to  rotate  the  wheels  in  a  forward  direction. 
If any of the wheels rotate, the brakes must be adjusted on that 
wheel. To adjust the brakes, release the Emergency Lever from 
its locked position and set the wheel brake adjustment up 2 or 3 
notches (refer to instructions on page 16). Repeat the test procedure 
as necessary.

MAINTeNANce

1.   Frequently  check  the  brake  fluid  level.  (Fluid  must  be  approved, 

clean and uncontaminated.)

 2.  Inspect  the  brake  tongue  and  brakes  and  replace  bent,  worn  or 

damaged parts.

3.   Be constantly aware of the system’s braking quality and make periodic  

checks.  Consult a certified brake specialist to make the necessary 
adjustments and/or repairs. Failure to do so could result in loss of 
braking.

seRvIcING The eMeRGeNcy leveR

If the Emergency Lever (#14) of the tongue is applied, it can be disengaged 
by using a screwdriver to lift upward on the front of the flat Emergency 
Lever Spring (#16) while pulling the lever forward until it releases.  A 
thorough inspection of the Emergency Lever, Emergency Lever Spring, 
and the Chain with S-Hooks is required and all damaged parts must 
be replaced as follows:
  
a.   Remove  the  Master  Cylinder  (#2)  and  the  Push  Plate  Assembly 

(#11).  Be careful not to get dirt into the Master Cylinder. (A new 
Master Cylinder Gasket (#3) should be used when reinstalling.)

b.   Remove  the  Safety  Chain  from  the  Emergency  Lever  (#14), 

Emergency Lever Guide (#17), and  flat  Emergency Lever Spring 
(#16), then pull the lever out of the tongue (#1)  from the bottom.

c.  Install the new Emergency Lever from the bottom of, and up through 

the slot in, the tongue. Attach the new Emergency Lever Spring, and 
the Emergency Lever Guide.

d.   Install a new Master Cylinder Gasket to the Master Cylinder and put 

the Push Plate Assembly and Master Cylinder back into the inside 
of the tongue.

e.  Squeeze shut the S-Hook of the Emergency Chain (#13) onto the 

Emergency Lever (#14).

f.  Add adequate brake fluid to the Master Cylinder and bleed the 

brake system per instructions 4-6 in the disassembly and reassembly 
section.

WARNING:

cAuTIoN

Summary of Contents for Gravity Flow 550

Page 1: ...Page 1 10 17 AG20021 Rev 1...

Page 2: ...hank you for purchasing a Demco Gravity Flow Wagon We feel you have made a wise choice and hope you are completely satisfied with your new piece of equipment Proper care and use will result in many ye...

Page 3: ...us situation that if not avoided could result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices caution Ind...

Page 4: ...erve all safety signs and practice instructions on them Never exceed limits of a piece of machinery If its ability to do a job or to do so safely is in question don t try it Lighting and marking It is...

Page 5: ...inspection for any loose bolts worn parts or cracked welds and make necessary repairs Follow maintenance safety instructions included in this manual Be sure there are no tools lying on or in equipment...

Page 6: ...rs of operation Correct all problems Follow maintenance safety procedures Following operation Following operation or when unhitching stop tractor or towing vehicle set brakes shut off engine and remov...

Page 7: ...ate engine of towing vehicle in a closed building Exhaust fumes may cause asphyxiation Before working on this machine stop towing vehicle set brakes shut off engine and remove ignition key Always use...

Page 8: ...t Turn Sharply G AG21002 Caution 20 M P H cAuTIoN do not exceed 20 MPh when loaded 09 99 AG21002 G D M F K K K B L H 04804 Red Reflector I AG21163 Large Demco Charcoal J 07278 Conspicuity w White to t...

Page 9: ...do not allow hub to turn 4 Tighten nut to final torque indicated on chart 5 Install cotter pin if needed loosen or tighten nut to the next closest locking slot 6 Check hub for end play 7 If end play...

Page 10: ...A B 7 34 12 19 For Breakdown of Tongue and Pivot Arm Assembly See Page 15 M Q O N R S T V X W W 13 Y 34 34 550 bushelw optional frontwheel brakes 8 8 5 5 1 1 2 2 3 3 6 6 7 7 8 8 9 9 10 10 11 11 12 12...

Page 11: ...R BOLSTER FRAMES ASSEMBLY INSTRUCTIONS REF PART QTY DESCRIPTION 1 07353 1 1 1 4 12 UNF Castle Nut 650 750 01934 1 1 14 UNF Castle Nut 550 2 05088 1 1 4 x 2 Lg Cotter Pin 650 750 00191 1 3 16 x 1 1 2 L...

Page 12: ...ld cause severe property damage personal injury and or death thewheels alwaysbeginwithwheelfarthestfromthemaster cylinder and move toward it Immerse the other end of the hose into a clean transparent...

Page 13: ...in 30 12122 30 1 Adjustable Tongue Male Half 31 07517 30 1 Tongue Extension Latch 32 01158 95 1 Latch Spring 33 07521 95 1 Latch Pin 34 00036 1 5 16 Lockwasher 35 01263 1 5 16 18 UNC x 3 4 Hex Head Bo...

Page 14: ...7M 1 Wheel Cylinder Assembly Left 4 SB9783 1 Push Rod 5 SB9254 2 Cover Plate Adjusting Hole 6 05961 2 5 16 18UNC x 5 8 Hex Head Bolt 7 05424 2 5 16 External Tooth Washer 8 05431 1 Bleeder Replacement...

Page 15: ...ake cluster first Then bendaroundthetopoftherearbolsterframeandattachtotheRear BrassTee 4 as shown Now attach 53 Steel Lines 9 to center of outlet on Brass Tee 4 along reach pipe 7 Assemble 12 Rubber...

Page 16: ...f abnormal wear is found such as brake shoe hitting brake drum once lining is gone rivets hitting brake drums and or brake drums out of round NOTE Maximum diameter allowed 13 060 Brake Set up 1 Attach...

Page 17: ...ks on the second click The lever should be approximately straight up and down Now try to rotate each of the four wheels inaforwardrotation Youshouldnotbeabletorotate the wheels forward If you can then...

Page 18: ...5 19 13 5 12 12 5 30 17 13 17 31 28 27 27 28 27 28 19 31 19 43 25 26 23 5 17 17 8 16 8 16 29 10 13 13 11 1 21 1 1 33 9 9 34 18 18 6 17 2 4 17 17 7 10 Red 20 Green 42 Blue Wagons are available in 3 col...

Page 19: ...3 Slide the Center Dump Chute 36 under the box Raise the Center Dump Chute and align holes with holes on the Unloading Chute 35 Bolt together using 3 8 x 1 3 4 bolts 7 and 3 8 Nylon InsertLocknuts 17...

Page 20: ...mounting bolts are tight Periodically check braking quality If you think they are a little soft check the movement on the actuator If it moves more than 7 8 the brake shoes need to be adjusted Failur...

Page 21: ...er plated Please order replacement parts by PART NO DESCRIPTION and COLOR REF PART NO NO QTY DESCRIPTION 11 12293 8 Plastic Bushing 12 13103 30 4 Bolster Bolt 13 13105 30 2 Torsion End Link 14 13107 3...

Page 22: ...6 18 UNC x 3 4 Gr 5 19 00907 2 3 8 16 UNC x 1 Gr 5 20 02592 2 3 8 16 UNC Nylon Insert Locknut 21 12443 30 1 Light Wire Cover REAR PLUG 3 1 2 1 3 Please order replacement parts by PART NO DESCRIPTION a...

Page 23: ...offset REF PART NO NO QTY DESCRIPTION Fender Assembly on 550 750 Gravity Flow Wagons 2 3 4 6 14 13 12 11 10 5 6 13 14 5 1 2 6 6 6 3 1 6 6 3 3 6 6 3 3 6 4 6 9 1 6 4 6 17 18 15 16 7 6 7 6 Mount Inner F...

Page 24: ...de Note Be Careful NOT to Drill through light wire Clamp fender mounts to wagon corner posts at dimensions shown above Using the fender mounts as a guide drill 11 32 dia holes through corner posts of...

Page 25: ...Page 25 NOTES...

Page 26: ...Page 26 NOTES...

Page 27: ...Page 27 NOTES...

Page 28: ...h St BOYDEN IA 51234 PH 712 725 2311 FAX 712 725 2380 TOLL FREE 1 800 54DEMCO 1 800 543 3626 www demco products com Go online to www demco products com for Demco warranty policies operator manuals pro...

Reviews: